Glassware forming apparatus with distributed control and method of operation

ABSTRACT

An improved electronic control system for glassware forming apparatus having a hierarchy of machine level supervisory controllers (including a machine controller and an operator communications controller), section controllers, and individual mechanism controllers. The mechanism controllers may be dedicated to the control of a variety of functions admitting of automated control, such as servo-control of electrical motors, sequencing of solenoid valves, generating alarm signals, etc. The mechanism controllers include separate control programs designed for their associated forming mechanisms, and are subject to on-off timing control in real time from the section level controllers. In general, the machine controller and operator I/O controller handle set-up, operator modifications during operation, and other &#34;non-real-time&#34; interactions with the mechanism controllers; the machine controller also coordinates the operation of a plurality of mechanism controllers in accordance with machine-level parameters.

BACKGROUND OF THE INVENTION

The present invention relates to automated glassware forming apparatus,and more particularly to improved electronic control systems for suchglassware forming apparatus.

A widely accepted type of apparatus for forming glassware articles,known as the Hartford I.S. (or "individual section") machine, isexemplified by U.S. Pat. No. 1,979,211. These machines incorporate amaster timing cam mounted to a machine drive shaft to actuate various"forming events" during each glassware forming cycle, by controllingvarious valves to pneumatically operate various mechanisms within eachmachine section. The specific motion of given mechanisms may be furthercontrolled by cams, pneumatic control mechanisms, and the like.Typically a given I.S. machine includes a plurality of sections (e.g.eight) which are coordinated in the infeed of molten glass from a commongob distributor, and in the removal of formed glassware articles forfurther processing.

With the advent of electronic process control technology, variousimprovements to the above machine design have been made in controllingthe timing of various forming operations. An initial stage of thisadaptation was the replacement of the mechanical timing control of themaster cam with digital electronic apparatus which generated actuationpulses for, e.g., solenoid-actuated valve blocks. See, e.g., U.K. PatentNo. 1,079,385. This electronic timing control was tailored to thespecial processing requirements of the glassware forming process in U.S.Pat. Nos. 3,877,915 and Re. 29,188, which characterized the machinetiming by critical thermodynamic milestones of the forming process--i.e."thermodynamic boundary events". These and other inventions providedincreasingly sophisticated machine-level timing control over formingevents, machine start and stop functions, and the like.

More recently, such electronic control systems have added an additionalheirarchy of section-level controllers; see, for example U.S. Pat. Nos.4,152,134; 4,247,317; and 4,478,629; and EPC application No. 84300470.6.Different systems employing such section-level controllers vary in suchcharacteristics as whether the section controllers are capable ofindependent operation (as opposed to requiring downloading from asupervisory machine controller), and the nature of operator interaction.All of these approaches offer only a limited, on-off control over theoperation of given forming mechanisms.

It is also known to provide some degree of feedback control over themechanisms of an I.S. machine and related machine elements. For example,the system of U.S. Pat. No. 4,108,623 employs feedback sensors in acentrally-oriented control system, which can vary the duration ofvarious timing events in response to the sensor output. Such systems,again, provide only a limited degree of control over given formingmechanisms.

Another recent development in the interest of improved speed,efficiency, and reliability of such glassware forming machines relatesto the drive mechanisms for I.S. machine components and related inputand output equipment. In lieu of the pneumatic and cam driven mechanismsof traditional glassware forming machines, various servo actuatorsystems have been incorporated for such mechanisms as the gobdistributor, bottle pushout etc. See, e.g., U.S. Pat. Nos. 4,367,087;3,871,858; 4,456,462; 4,461,637; 4,427,431; and 4,409,013. These deviceshave not, however, been effectively integrated in a comprehensiveelectronic control system, but have entailed stand-alone controllerswith quite limited interactions with the machine and sectioncontrollers.

European Patent Application No. 84105048.7, filed May 6, 1983, disclosesa glassware forming machine electronic control system wherein machinecomponents are mechanically linked to digitally responsive motormodules. The digitally responsive motor modules are under control of acomponent controller which is actuated by a conventional electronictiming control system of the type discussed above. This system isdesigned for an all-electric glassware forming machine, and does notaccommodate a partially pneumatic, partially servomotor drive, machinedesign. In addition, this system provides only a limited degree ofdistributed control over various machine functions.

Accordingly, it is a principal object of this invention to achieveimproved automation of glassware forming apparatus. A related object isto achieve a higher degree of control over given mechanisms within suchapparatus. A further related object is to effectively integrateservo-controlled forming mechanisms within glassware forming machines.Such control system should enjoy a flexible design, permitting selectiveuse of servomotor control, solenoid valve control, and a variety ofother electromechanical interfaces.

Another object is to improve user-interaction in an electronic controlsystem. A related object is to improve the physical design ofelectronically controlled glassware forming machines, thereby to improvethe operating environment.

A further object is to improve the efficiency of glassware formingapparatus. As one aspect of this, it is important to reduce "down-time"in the inevitable event of wearing-out of parts, malfunction ofmechanisms, etc. Futhermore, it is desirable that a malfunction of givenforming mechanism not disable the operation of an entire I.S. machineand be easily diagnosed and serviced.

SUMMARY OF THE INVENTION

In furthering the above and related objects, the invention provideselectronic control apparatus for glassware forming machinery whicheffectively integrates dedicated, mechanism-specific controllers in asystem heirarchy. Principal elements of such control system are themechanism controllers, one or more section controllers, and a machinecontroller. Advantangeously the control system also includes an operatorcontrol processor, and input-output devices for operator interaction.Such control systems may be used in conjunction with one or moreservo-controlled forming mechanisms, optionally in cooperation withconventional cam and pneumatic drives for other machine components.

According to one aspect of the invention, the dedicated mechanismcontrollers comprise user-programmable logic elements which store acontrol program for one or more operational components of the I.S.machine. The mechanism controller receives user-specified set-upparameters from the machine controller, said set-up parameters beingcharacteristic of the particular machine element and the actions beingcontrolled. The set-up parameters may be entered by the operator usingthe machine terminal before start-up or modified during operation, andare downloaded from the machine controller to the mechanism controller.The mechanism controller also receives one or more timing signals fromthe section controller, and processes these signals together with theset-up parameters to generate one or more output control signals to therelated operational component.

The machine controller also may receive sensor outputs and otherinformation concerning the mechanism environment, and may transmit thisinformation together with other mechanism status signals to the machinecontroller for feedback control or operator interaction. For glasswareforming mechanisms of sufficient complexity, the mechanism controllermay comprise a principal mechanism controller together with subsidiarymechanism controllers which regulate subsystems of the operationalcomponent.

Another aspect of the invention relates to the nature of the section andmachine controllers of such systems. One or more section controllersproduce "timing drum" signals in the manner disclosed, e.g., incopending application U.S. Ser. No. 461,086, now abandonded filed Jan.26, 1983, i.e. it regulates the on and off times of the sectioncomponents within the forming cycle. In contrast to the "real time"control provided by the section controllers, the machine controller andoperator I/O controllers are responsible for set-up, operatormodifications during operation, and other "non-real-time" interactions.The machine controller also coordinates the operation of a plurality ofdedicated mechanism controllers.

A further aspect of the invention is the nature of system communicationelements. To achieve real-time adaptive control, this system employsbidirectional communications among the mechanism, section, andmachine-supervisory controllers, and various input/output devices.Desirably, the system includes an asynchronous communication linkbetween the machine controller and the mechanism controllers, said linkmost preferably having multidropping capability. A bidirectional linkbetween the machine controller and mechanism controllers passes set-upparameter signals in one direction, and mechanism processor statussignals (such as alarm signals) in the other.

In a particular operative embodiment of the invention, each of aplurality of mechanism controllers is dedicated to controlling multiplefunctions of a corresponding pushout assembly. Controlled functionsinclude the actuation and deactuation of various solenoid valves, andthe profile of a stepper motor shaft rotation. Electronic control isaccomplished by a pair of outputs--pocket air and pusher startsignals--from the section controller to each pushout controller. Thetiming signals from the section controllers comprise pulses, which areprocessed by the pushout controller to extract timing information fromthe pulse widths. The pulse rise times control pushout controlleroutputs in real time, while the extracted timing data regulate pushoutcontroller outputs in non-real-time.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and additional aspects of the invention are illustrated in thefollowing detailed description of the preferred embodiment, takentogether with the drawings in which:

FIG. 1 is a schematic block diagram of a preferred control architecturein accordance with the invention, for control of a glassware formingmachine;

FIG. 2 is a diagrammatic view of the machine terminal shown in FIG. 1;

FIG. 3 is a schematic block diagram of a pushout control system inaccordance with the invention;

FIG. 4 is a schematic block diagram of the pushout controller of thecontrol system of FIG. 3;

FIG. 5 is a perspective view of a pushout assembly in accordance withcommonly assigned U.S. Ser. No. 741,017, filed June 3, 1985, now U.S.Pat. No. 4,557,746 incorporating the controller of FIG. 4;

FIGS. 6A-6E are timing diagrams showing time-vs.-voltage plots ofvarious signals of the section controller and pushout controller:

FIG. 6A plots the pocket air signal of the section controller, inmachine degrees;

FIG. 6B plots the pushout start signal of the section controller, inmachine degrees;

FIG. 6C plots the extend/retract signal of the pusher controller, inpushout degrees;

FIG. 6D plots the cylinder rotate signal of the pusher controller, inpushout degrees;

FIG. 6E plots the pocket air signal of the pusher controller, in pushoutdegrees; and

FIG. 6F plots the pushout cam profile, in pushout degrees;

FIG. 7 is a flow chart schematic diagram of a startup routine for thepusher controller;

FIG. 8 is a flow chart schematic diagram of an operating routine for thepusher controller;

FIG. 9 is a circuit schematic diagram of an opto-isolator input circuitfor the pusher controller circuit of FIG. 4;

FIG. 10 is a circuit schematic diagram of a motor drive circuit for thepusher controller circuit of FIG. 4;

FIG. 11 is a circuit schematic diagram of a solenoid drive circuit forthe pusher controller circuit of FIG. 4;

FIG. 12 is a schematic block diagram of a dedicated mechanism controllerfor a takeout mechanism; and

FIG. 13 is a schematic block diagram of a dedicated mechanism controllerfor an invert mechanism.

DETAILED DESCRIPTION

Reference should now be had to FIG. 1, which illustrates the systemarchitecture of a distributed control system 10 for glassware formingmachines. Control system 10 may be conveniently understood as consistingof a number of subsystems, generally indicated by the dashed lines.Section controllers 150-1, 150-2, . . . , 150-N comprise the real-time,"timing event" portion of the system, including a plurality ofindividual section controllers typically of the type disclosed incommonly assigned U.S. Pat. Application Ser. No. 461,086, filed Jan. 26,1983. Each of section controllers 150 is assigned to a different sectionof an n-section glassware forming machine, typically an "I.S. formingmachine". Section controllers 150 and Machine controller 130 receivetiming pulses from Timing Pulse Generator 170, to synchronize theoperation of the various sections. The phased operation of each sectionis determined by a program within each controller 150 which offsets itsrespective starting point by a predetermined amount from thesynchronizing pulse. Each Section controller 150 generates a group of"timing drum" outputs defining the respective times within thatsection's operating cycle when various mechanisms are to be actuated ordeactuated, or other actions are to be taken. As shown in FIG. 1, theseoutputs may be routed directly to valve blocks 470 or other interfacingdevices as is typical in the prior art, or may be transmitted toindividual "mechanism controllers" 200-1, 450-1, 460-1 etc. for thatsection. Thus, the real time information from section controllers 150may be supplied in a format analogous to conventional timing systems forI.S. machines, and a given I.S. machine may combine distributedprocessing of some section mechanisms with conventional "electronictiming drum" control of other mechanisms.

The machine controller 130 and Supervisor Controller 180 comprise the"non-real-time" portion of system 10. Controller 130 suppliesmechanism-specific timing set-up information, ("set-up parameters")during both initial set-up and while running the system. Machinecontroller 130 includes a resident program to allow it to support thefunctioning of a variety of mechanism controllers.

Supervisor controller 180 supports operator communication via a machineterminal 110, printer 111, tape unit (mass storage device) 112, or otherperipheral devices. Supervisor controller 180 communicates with themachine controller 130 and with the section controllers 150 viabidirectional communications links 181, 182 to deliver parametersentered by the user at terminal 110 or from mass storage unit 112, andto enable the printout and display of data.

A set of mechanism controllers 200-1, 450-1, 460-1 are shown forsection 1. In addition to the one-way timing signal channels 155 fromsection controller 150-1, the mechanism controllers communicate withmachine controller 130 via bidirectional data link 135. Data link 135passes set-up parameter signals from the machine controller 130 to themechanism controllers, e.g. to download parameters entered at terminal110. Data link 135 also transmits mechanism controller status signalsfrom the mechanism controllers to machine controller 130, such asalarms, information about the mechanism environment, etc.Advantageously, data link 135 comprises an asynchronous multidrop dataline. This mode of transmission simplifies wiring, interconnecting, andinstallation.

Advantageously, each of the various mechanism controllers for a givensection are physically associated with the mechanism which it isdesigned to control--e.g. pushout controller 200 (FIG. 5). Thus, if amalfunction occurs in a given mechanism, whether mechanical orelectrical, the offending part may be easily removed and replaced.

As illustrated below with respect to pushout control system 100 (FIG.3), the control architecture of the invention provides many of the wellknown advantantages of distributed control. The control of eachmechanism may be adjusted individually and dynamically, and thecontrolling processes for each mechanism's actions or motions are easilyprogrammed or changed.

It should be understood that the system architecture of FIG. 1illustrates the general functional interrelationship between variouscomponents of control system 10, and that the block make-up of suchsystem does not necessarily identify discrete hardware modules. Forexample, a single section controller 150 may be provided for a pluralityof machine sections, such controller including means for distinguishingtiming outputs for different section. The machine controller 130 andsupervisor controller 180 may comprise a single computer, and themachine terminal 110 may be integral with the supervisor controller orthe combined supervisor/machine controller. The mechanism controller mayconsist of a master controller to control principal mechanism actions,and a subservient controller to control a dependent subsystem of themechanism.

FIGS. 3-8 illustrate a particular embodiment of a dedicated mechanismcontrol system 100 embodying the universal controller architecture ofFIG. 1, for controlling a plurality of pushout assemblies. FIG. 5 showsa pushout assembly 50 in accordance with commonly assigned U.S. Pat.Application No. 741,017, filed June 3, 1985, which is a continuationapplication based upon U.S. Ser. No. 520,396, filed Aug. 4, 1985 nowabandoned. The following explanation of the operation of pushout 50provides a background for a discussion of the dedicated pushoutcontroller 200. Controller 200 is shown here packaged as a singleprinted circuit card 201 plugged into an STD bus compatible backpane 52,for convenient installation and maintenance.

Pushout 50 relies upon a combination of pneumatic and electricalpower--pneumatically powered pushout/return and extend/retract functions(controlled via solenoid valves), and an electrically controlled pushoutprofile. Prior to the start of pushout, air is directed to the undersideof the piston 71 in rotary actuator 70, upward movement of piston 71being prevented by nut 73 on lead screw 75. A source of "pocket air"(not shown) has been turned on to assist the nesting of a container inpusher cylinder fingers 83. At the start of a pushout cycle, steppermotor 60 begins to rotate at a rate determined by a pushout profile("pushout cam"). Nut 73 moves up lead screw 75, allowing piston 71 tomove.

A helical splined shaft 78 is fixed to the upper part of piston 71, andengages a helical splined nut (not shown), so that as the shaft 78passes through the nut it causes the nut to rotate. This rotation istransferred to pusher cylinder 80, thus controlling the sweepoutprofile. At a variable point prior to completion of sweepout, a solenoidvalve (not shown in FIG. 5) switches and retracts the pusher cylinderfinger 83, and when this mechanism returns the valve switches again toextend finger 83 over dead plate 81. Another solenoid valve (not shown)switches to turn off the supply of pocket air prior to completion ofsweepout.

At the completion of pushout, the solenoid valve (not shown in FIG. 5)controlling the air to piston 71 switches, diverting the air to theupper part of the piston cylinder. The nut 73 on lead screw 75 does notprevent motion in the reverse direction so that piston 71 returns underpneumatic power. Stepper motor 60 is reversed, returning nut 73 to its"home position", where it actuates a proximity sensor 65 to signalcompletion of the pushout cycle.

FIG. 3 schematically illustrates at 90 various electronic controlelements which act in concert with a given pushout controller 200 forcontrolling the electrical and pneumatic functions of a given pushout50. Pusher Controller 200 communicates with Machine controller 130 by aserial multi-drop communications line 132, which is also connected toindividual pushout controllers for other sections (not shown), providingasynchronous machine data transmission at 300 baud. All pushoutcontrollers simultaneously receive non-time-critical data common to thewhole I.S. machine; there are also individual broadcasts of pushout"cam" profiles. Alarm line 134, illustratively 24 VDC, transmits errormessages from the various pusher controllers 200 to machine controller130, for example to request rebroadcast of information via serial line132.

Advantageously, section controllers 150 takes the form disclosed incommonly assigned U.S. patent application Ser. No. 461,086 filed Jan.26, 1983. The Section controller 150 for section N provides a pair of 24VDC pulse outputs to Pushout Controller 200 to actuate and deactuatetime critical pushout functions. The first of these signals is thepocket air signal 300 (FIG. 6A). Its rising edge signals pushoutcontroller to turn on pocket air--i.e. actuate pocket air solenoid valve91. The width of pulse 300 is then measured and used to calculate whento deactuate pocket air solenoid 91 after rotary actuator 70 hastransversed an indicated number of degrees of arcuate motion. Thesecond, "pushout start" signal 310 is interpreted similarly, actuatingsolenoid 93 and initiating rotation of rotary actuator 70 (FIG. 5) onits rising edge, and retracting fingers 83 by deactuating solenoid valve95 after a calculated number of degrees based on the width of pulse 310.Details of the control algorithm are explained below.

Advantageously, pocket air solenoid valve 91 is a two way valve whichturns pocket air on when energized; cylinder rotate solenoid valve 93 isa four way valve which is deenergized when the pusher cylinder 70 is inits home position; and extend/retract solenoid valve is a four way valvewhich when energized extends fingers 83.

Timing pulse generator 170 provides a machine synchronization signalonce per machine cycle, to Section controller 150 and Machine controller130. Machine controller 130 measures the time between pulses over aseries of consecutive pulses, and recognizes machine synchronization ifthe pulses are within a valid machine cycle range, and the times betweenrising edges remain within a permitted variation. If timing signal 170is lost after synchronization, the pusher timing cycle will continue torun at the last measured cycle time. If the signal returns whencontroller 200 is in pseudo-synchronization, Machine controller 130measures the new pulse train and re-synchronizes based on the newsignal. As long as the time between rising edges changes by less thanthe permitted variation, the section controller 150 and pushoutcontrollers 200 remain synchronized.

Alternatively, in the absence of an external sync source 170, theoperator may define a pusher timing cycle by entering a cycle timing inMachine Terminal 110.

Supervisor Controller 180 supports operator communication with machineterminal 110 (as well as possibly with other peripheral devices, such asthe printer 111 and mass storage unit 112 shown in FIG. 1). As shown inFIG. 2, machine terminal 110 includes a two line display 113 whichdisplays system messages and prompts. The keyboard 115 consists ofvarious numeric and function keys. The DO key causes a selected actionto be taken; the NEXT key displays the next node or sub-node title ofthe menu screens; EXIT returns to the first node; JOG UP and JOG DOWNchange the current displayed numeric entry by a constant amount; ENTERenters the current displayed numeric information into the database ofSupervisor Controller 180; CLEAR clears information just entered withoutchanging controller values; and Section/Event allows access to a Sectioncontroller 150. Machine terminal 110 is used both to enter initialparameters to be downloaded into pushout controller 200, and to modifythese parameters (possibly during system operation). Machine terminal110 is adapted to operator supervision of multiple mechanism controllerby including an appropriate set of menu screens for each mechanismcontroller. Menu screens may also be provided for machine componentsinterfaced via valve block 470 (FIG. 1).

FIG. 4 shows in block diagrammatic form the various functional elementsof the dedicated pushout controller 200. In the preferred embodiment ofthe invention, pusher controller comprises an integrally mounted circuitcard 201 which houses a microprocessor, a unipolar chopping steppermotor drive, and other input/output conditioning circuitry. CPU 210handles serial communication with Machine controller 130, and controlsthe operation of the other microprocessor elements in accordance with acontrol program stored in ROM 215. In an operative embodiment of theinvention, CPU 210 comprises an 8085 AH microprocessor of IntelCorporation. Serial communication is handled via a differential linereceiver (not shown) using the 8085 SID input line. Counter/Timercircuit 213 is connected to the CPU's data/address bus 240.Illustratively, C/T 213 contains three independent programmablecounters, the inputs of which are connected to the clock outputs of CPU210, with the counter/timer outputs connected to the CPU's interruptinputs. C/T 213 is used for communications synchronization, CPU timing,and motor step timing.

RAM 218 stores the current pusher cam profile and acts as a scratch padmemory for CPU 210. A variety of data mapping techniques well known inthe art may be employed for the digital representation of the pusher camprofile within RAM 218. Illustratively, RAM 218 comprises a 1K×8 bitstatic random access memory integrated circuit. ROM 215, which storesthe controller's program code, illustratively consists of a 4K×8 bitRead Only Memory connected to address/data bus 240.

Input port 220, also connected to address/data bus 240, monitors thestatus of home sensor 65 (FIG. 5), and receives the pusher start signaland pocket air signal from Section controller 150. Advantageously, thepushout controller 200 includes input signal conditioning circuitry 225,for DC level-translation, isolation, filtering, and noise rejection. Anopto-isolator circuit 225 as illustrated in FIG. 9 may be used toprovide both electrical isolation and level translation (24 VDC input to5 VDC CPU signal level). Resistor R2 is selected so that approximately12 VDC must be present at the input before the microprocessor detects achange at input port 220. Resistor R1 act as a low pass filter to rejecthigh frequency noise. Output latch 230 is connected to CPU 210 via theaddress/data bus 240. Advantageously, two such latches are provided, onebeing connected to motor drive circuit 235 to switch on and off variousmotor phase signals φA-φD, the other to solenoid driver circuits 250.Latches 230 provide four bit parallel output ports under the control ofCPU 210.

Illustratively, pusher controller 200 employs a unipolar choppingstepper motor circuit 235 of the type shown in FIG. 10 for driving thestepper motor 60 of FIG. 5. (FIG. 10 shows one half of the drivecircuit). Before turning on motor 60 both N-channel phase switches (e.g.driver transistor Q1 and diodes CR1 and CR2) are off and no currentflows through resistor R4. P-channel FET Q3 is therefore on at thispoint. When motor 60 is to take a step, the discrete coil winding forphase A (for example) is energized by changing the gate voltage from 0VDC to 12 VDC, allowing current to flow through Q1 and Q3. Current willcontinue to flow through φA until the voltage level across R4 equals thereference voltage established by U2 and R5. When this happens one-shotU3 is triggered to turn off FET Q3 for 0.5 msec. On the timing out ofone shot U3, Q3 will be turned back on, and the cycle repeated for aslong as the φA signal is provided by output latch 230 (FIG. 4). Thisarrangement allows "overdriving" of the stepper motor 60 without largeseries resistors.

FIG. 11 illustrates an advantageous output driver circuit 250 of thetype used to actuate and deactuate the various solenoid valves 91, 93,and 95 (FIG. 3). Output driver 250 converts the microprocessor commands,in the form of 5 VDC signals, to 24 VDC drive signals for the pushersolenoids (up to 1 ampere inductive load). U24 comprises an optoisolatorwhich is driven by the 5 VDC signal from output latch 230 (FIG. 4).Turning on U4 allows current to flow through R7 and R8, thereby turningon Q4 and energizing the load. Diode CR6 protects switch Q4 frominductive loads.

When the operator wishes to set up and run the pusher control system100, he depresses the maintenance stop button 116 on machine terminal110 (FIG. 2), and turns on the power supplies to the variouscontrollers. Table 1 lists in order the displays which are associatedwith the menu-driven software and are used by terminal 110 for inputtingand displaying various data for the pushout control system. Menuselection relies in particular on three keys of terminal 110--the DO keyto execute the currently displayed item, the NEXT key for displaying thenext item in the menu, and the PREVIOUS key for displaying the previousmenu item.

During the setup phase, the user selects various required parametersincluding the desired cam profile. These may be later modified duringoperation of pushouts 50 for fine-tuning. Referring to Table 1, themaster offset angle represents the number of machine degrees offset fromthe sync signal of the pushout cycle for each section, which may beadjusted to maximize the container dead plate time. "Pocket air on"gives the number of machine degrees before the start of pushout, while"pocket air off" gives the number of pushout degrees (arcuate degrees)upon which pocket air is turned off; these may be adapted to control the"nesting" and stability of containers held by fingers 83 (FIG. 5). CamProfile Select (Item B1) enables the user to select the part of numberof a desired pushout cam (stepper motor drive profile) from a profilechart. Cam Speed (C1) permits operator variations of pushout speedwithin certain limits, and may be used to adjust the release ofcontainer from the pusher fingers 83 to an outfeed conveyor. PushoutStart (D1) permits fine adjustment of pushout firing order, whileRetract Angle (D2) corrects various mechanical problems associated withmistimed finger retract.

After set-up of the pusher controller has been completed, the pushoutsections may be started individually by releasing the maintenance stopbutton 116, selecting the appropriate section under the "Section Status"menu item E1 (Table 1), and turning on Machine controller 130. Thiscommences down loading of data to pushout controller 200.

FIG. 7 is a block schematic diagram of the startup routine of the pushercontrol program in ROM 215 (FIG. 4). When power is applied to themicroprocesor, the following intializating steps occur:

(1) All solenoid valves are turned off.

(2) RAM check

(3) The alarm line 134 rises to 24 VDC and remains on for 100 ms.

(4) In response to (3) the Machine controller 130 transmits a cam andrelated information.

(5) The cam is checked for validity; the routine reverts to (3) above ifthe cam is found invalid.

(6) Upon receiving a valid cam, Pushout Controller 200 is initializedand will wait for signals from the Section controller 150 on thepocket-air and pushout start signal lines.

When a given Pushout Controller 200 detects a rising edge on the pusherstart input line 154, it actuates the extend/retract solenoid valve,then measures DELTAST, the time between two rising edges of the pusherstart pulses (step 368). Pulse widths of the pocket air and pusher startsignals are also measured at 370. Using the measured value for DELTAST,which is machine cycle time, and the measured pulse widths, the "pocketair on time" and "finger retract time" are each calculated using thefollowing formula: ##EQU1## where s=number of motor steps until event

ΔT=pulse width time

T=machine cycle time

N=number of motor steps in 90° pusher rotation.

TABLE I Pushout Menu Selection

A. Machine Data

A1. Master Offset

A2. Pocket Air On

A3. Pocket Air Off

A4. Number of Pushout Sections

A5. Firing Order

B. Cam Profile Select

B1. Profile - Selection Table

C. Cam Speed

C1. Cam Sweepout Time Variation

D. Event Table

D1. Pushout Start Angle

D2. Retract Angle

E. Section Status

E1. Pushout Section on/off

F. Alarms

F1. Number of Alarm Conditions

F2. Alarm Messages

The pulse width of the pocket air signal is used to communicate thenumber of degrees of arcuate motion through which the pusher cylindermust rotate before pocket air is turned off. Similarily, the pulse widthof the pusher start signal is used to communicate the number of degreesof arcuate motion through which the pusher must rotate before the pusherfingers are retracted. The above formula is used to calculate the numberof motor steps associated with pocket air off (S1) and finger retract(S2). Thus, with reference to the timing diagrams of FIGS. 6A-6F, thepulse width T1 of the Section controller pocket air signal 300 (FIG. 6A)determines the cut-off time S1 of the Pusher Controller pocket airsignal (FIGS. 6E, 6F). The pulse width T2 of the pushout start signal310 (FIG. 6B) determines the cut-off time S2 of the extend/retractsignal (FIGS. 6C, 6F); both S1 and S2 are within the "sweepout" phase410 of the arcuate motion profile. Note that the pulse widths are usedto communicate information only via the above formula, and no real timeevent is associated with the falling edges of the pusher start andpocket air pulses 300, 310.

DELTAST is measured between the first and second pusher start pulses,and between the second and third, at 368. These measurements are testedat 371, 373 to determine whether the cycle time exceeds a requiredminimum MINDEL, and whether the successive DELTAST measurements aresubstantially equal (± 2%). If these tests are passed, the programcalculates and stores S1 and S2 according to the above formula, andscales the entered cam profile according to the machine cycle time(DELTAST). The microprocessor then instructs the motor 60 to rotate nut73 to its home position, and when this is verified at 381, enters theoperating loop.

FIG. 8 sets forth the operating steps which are repeated at each pushoutcontrol cycle (see the timing diagrams of FIGS. 6A-6F). At 385-6 thepocket air solenoid is energized upon detecting the rising edge of the"pocket air" signal. At 388-9 the cylinder rotate valve is energized inanticipation of the next "pusher start" signal. When this signal isdetected, the microcomputer measures and stores the current DELTASTvalue--i.e. the time between the current start signal's rising edge andthe last one received and stored.

The loop comprising steps 392-397 rotates the pusher cylinder accordingto the newly scaled cam profile. When the pushout rotates the propernumber of degrees, pocket air is turned off (at motor step S1), and thefingers are retracted (at motor step S2). When the pusher has rotatedcompletely, the microprocessor switches the cylinder rotate solenoid toallow the pusher cylinder 70 to return, then (after an interval)instructs the motor to return the nut to its home position. After afixed time T3 has elapsed since commencing reverse rotation of motor 60,the extend/retract solenoid 95 is energized to extend fingers 83. The"pocket air" and "pusher start" signals are again measured, to calculateand store S1 and S2, and the cam is rescaled for the last-measured valueof DELTAST. This prepares the system for the next cycle.

If during normal operation pushout motor 60 is unable to rotate due toan internal or external jam, the microprocessor will react according tothe scheme:

(1) De-energize extend/retract solenoid.

(2) De-energize cylinder rotate solenoid.

(3) Step motor 60 to attempt to move the nut to its home position, untilsuccessful.

(4) Resume normal operation upon next start signal.

The dedicated pushout control system discussed above illustrates thebasic principles of the invention in a particular system architecture(FIG. 3), dedicated controller design (FIG. 4), and suitable set-up andoperating procedures. These may be appropriately extended to systemscombining the universal controller architecture of FIG. 1, and similararchitectures, with other types of dedicated mechanism controller. Forexample, the pushout controller 200 has been illustrated in the contextof a given set of inputs and outputs to mechanism controller200--solenoid valve driver and motor driver outputs, and home positionsensor inputs. Such mechanism controllers may be applied to a widevariety of digital, analog, and serial inputs and outputs (includingboth control and communication devices). Illustrative control andcommunication devices include push buttons, pilot lights, solenoidvalves, motors, control valves, process control transmitters (fortemperature, pressure, etc.), keyboards, alphanumeric displays, etc.

FIG. 12 illustrates a mechanism controller 450 dedicated to the controlof a takeout assembly of a glassware forming machine. Takeout controller450 includes a serial line 451 which communicates with the machinecontroller, and a series of timing signal lines 452-454 which transmitsignals from a section controller (not shown). Advantageously, lines452-454 transmit Takeout Out, Takeout In, and Tongs Close signals,respectively, for real time control of the primary takeout actions. Theactual motion profile of the takeout arm is governed by takeoutcontroller 450, by means of parameter or table data downloaded viaserial line 451. An appropriate program for the takeout arm trajectorycould take into account predetermined dimensions and other physicalcharacteristics of the glassware article for a given job, such databeing entered by the user at machine terminal 110 (FIG. 1).

Takeout controller 450 can also monitor its own status and the status ofthe controller takeout assembly, including such information as motorcurrent, air pressure, and mechanism failure modes. Such informationcould be obtained from one or more sensors 457 and used to diagnose oranticipate operational problems. For example, a deviation of the motorcurrent (measured at 458) from its normal range might indicate mechanismwear or a binding problem before a failure actually occurs. Other alarmsmight be reported via alarm line 455 after the mechanism has failed.Such information would help the operator determine the cause of themalfunction and take appropriate corrective action.

FIG. 13 illustrates still another mechanism controller 460, for aninvert assembly. Real time control signals 462, 463 include invert andrevert signals. Controller 460 would operate similarly to takeoutcontroller 450, discussed above.

While reference has been made above to specific embodiments, it will beapparent to those skilled in the art that various modifications andalterations may be made thereto without departing from the spirit of thepresent invention. Therefore, it is intended that the scope of thisinvention be ascertained by reference to the following claims.

We claim:
 1. An improved electronic control system for a glasswareforming machine, said forming machine including a plurality of machinesections each section having a plurality of functional componentsoperating in phased relationship within a machine cycle for receivingmolten glass and molding glassware articles therewith, said controlsystem including at least one section controller for producing timingsignals representing actuating and deactuating times of operationalcomponents of at lest one section of said forming machine,theimprovement wherein said timing signals comprise pulse signals, furthercomprising a timing processor for receiving said pulse signals and forcalculating timing data based upon the pulse widths of said timingsignals, said timing processor comprising means for receiving the pulsesignal during each machine cycle, outputting a component actuatingsignal at the leading edge of said pulse signal, and calculating a timedelta signal proportional to the pulse width of said pulse, clock meansfor tracking elapsed time within an operating cycle of said timingprocessor, and means for comparing the time delta signal with theelapsed time and for providing a component deactuating signal at anappropriate point within the timing processor cycle.
 2. Apparatus asdefined in claim 1 wherein said first output signals comprise componentactuating signals, and said second output signals comprise componentdeactuating signals.
 3. Apparatus as define in claim 1, including aplurality of timing processors each dedicated to the control of a givenfunctional component.
 4. Apparatus as defined in claim 1, furthercomprising means for scaling the timing processor cycle according to themachine cycle time between successive pulse signals.
 5. Apparatus asdefined in claim 4 wherein the scaling means operates once per machinecycle to rescale the timing processor cycle.
 6. For use with anelectronic control system for a glassware forming machine, said formingmachine including a plurality of machine sections each section having aplurality of operational components operating in phased relationshipwithin a machine cycle for receiving molten glass and molding glasswarearticles therewith, said control system including at least one sectioncontroller for producing pulse timing signals representing actuatingtimes of functional components of at lest one section of said formingmachine, and a machine controller for controlling the setup of saidforming machine using a plurality of setup parameters,a mechanismcontroller for a given functional component of a given section of saidforming machine, said mechanism controller comprising:a processor; aclock means for tracking elapsed time within an operating cycle of saidmechanism controller; non-volatile control program memory means forstoring a control program for said processor, responsive to the leadingedge of each pulse tming signal to provide a first component actuatingsignal, and to the pulse width of said pulse signal to generate a timedelta value and comparing this value with the elapsed time to provide asecond component actuating time, wherein during each mechanismcontroller cycle a second component actuating signal is generated basedupon the second component actuation time determined during the previouscycle.
 7. A method for controlling a glassware forming machine, saidforming machine including a plurality of machine sections each sectionhaving a plurality of operational components operating in phasedrelationship within a machine cycle for receiving molten glass andmolding glassware articles therewith, and a control system including atleast one section controller for producing pulse timing signalsrepresenting actuating times of one or more functional components of atleast one section of said forming machine and a machine controller forcontrolling the setup of said forming machine using a plurality of setupparameters, said control method comprising the steps, repeated at eachmachine cycle, of:receiving at least one of said pulse timing signalsfrom said section controller; generating a first component actuatingsignal at the leading edge of said pulse timing signal; measuring thewidth of said pulse timing signal and producing and storing a time deltavalue based upon such pulse width; generating a second componentactuating signal delayed from said first component actuating signal by atime delta value produced during a previous machine cycle; andoutputting said first and second component actuating signals to one ofsaid functional components.
 8. A method as defined in claim 7 whereinthe time delta value is proportional to the pulse width from which it isproduced.
 9. In a glassware forming machine of the type including aplurality of machine sections each having a set of operationalcomponents for receiving gobs of molten glass and molding the glass intoglassware articles, said sections operating in phased relationshipwithin cycles of operation, an electronic control system for controllingthe operation of said machine components including:a section controller,for generating a series of timing signals for at least one section todefine actuation and deactuation times within the machine cycle; amachine controller for providing set-up parameters representative oftiming set-up information for at least one of said operationalcomponents; at least one mechanism controller for each machine section,for controlling the operation of a given operational components thereof,said mechanism controller containing a control program for thatcomponent, and a processor; a bidirectional asynchronous communicationslink between said machine controller and said mechanism controller, forpassing set-up parameter signals from said machine controller to saidmechanism controller and for passing alarm signals from said mechanismcontroller to said machine controller (1) to signal alarm conditionsidentified by said control program, or (2) to cause said machinecontroller to download said set-up parameters, wherein said mechanismcontroller produces at least one control signal for said operationalcomponent in response to the timing signals and in accordance with theset-up information and control program, and wherein the timing signalfrom said section controller comprises a pulse signal the leading edgeof which acts as a first timing signal for the associated machine cycle,and during each machine cycle the mechanism controller generates a deltasignal proportional to the width of the pulse signal received duringthat cycle, and processes the delta signal during a succeeding machinecycle to provide a second timing signal.
 10. For use with an electroniccontrol system for a glassware forming machine, said forming machineincluding a plurality of machine sections each section having aplurality of operational components operating in phased relationshipwithin a machine cycle for receiving molten glass and molding glasswarearticles therewith, said control system including at least one sectioncontroller for producing timing signals representing actuating anddeactuating times of functional components of at least one section ofsaid forming machine using a plurality of setup parameters,a mechanismcontroller for a given functional component of a given section of saidforming machine, said mechanism controller comprising: a processor;non-volatile control program memory means for storing a control programfor said processor, responsive to at least one of said timing signalsand to said set-up parameters, to define control outputs to saidfunctional components; a serial input port for receiving setupparameters from a machine controller; at least one output interface foroutputting control signals to said functional component in response tocommands from said processor; said control program being designed toinitiate alarm signals from said mechanism controller to said machinecontroller to indicate predefined alarm conditions or to requestdownloading of data from said machine controller, and said controlprogram being further designed to interpret set-up parameters downloadedfrom said machine controller to said mechanism controller, wherein thetiming signal from said section controller comprises a pulse signal theleading edge of which acts as a first timing signal for the associatedmachine cycle, and wherein during each machine cycle the mechanismcontroller generates a delta signal proportional to the width of thepulse signal received during that cycle, and processes this delta signalduring a succeeding machine cycle to provide a second timing signal.